Coal liquefaction process

Claim 2

A process comprising liquefying feed coal in a liquefaction zone at liquefaction conditions of temperature, pressure and residence time in the presence of hydrogen with recycle solvent including distillable and non-distillable coal liquids and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream, comprising the hydrocarbons boiling above 700° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia, CO x and water vapor, passing said entire effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said vapor stream, removing distillate liquid from said effluent liquid slurry stream to obtain non-distillable coal liquids and recycling to said liquefaction zone to extinction the 700° F.+ fraction of said distillate liquid, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.

Claim 3

The process of claim 1 wherein said feed coal is bituminous coal.

Claim 4

The process of claim 1 wherein said feed coal is sub-bituminous coal.

Claim 5

The process of claim 1 wherein said feed coal is lignite.

Claim 6

The process of claim 1 wherein said hydrotreater catalyst comprises Group VI-Group VIII metal on a non-cracking support.

Claim 7

The process of claim 1 wherein said hydrotreater catalyst comprises Group VI-Group VIII metal on alumina.

Claim 8

The process of claim 1 wherein said hydrotreater catalyst comprises nickel-molybdenum-alumina.

Claim 9

The process of claim 1 including the addition to said liquefaction zone of pyrite or a material which forms iron sulfide in said liquefaction zone.

Claim 10

The process of claim 1 including the additional step of recovering a naphtha stream from said hydrotreated product oil stream.

Claim 11

The process of claim 9 wherein said naphtha stream contains less than 2 parts per million of nitrogen.

Claim 12

The process of claim 9 including the additional step of passing said naphtha stream to a reformer zone.

Claim 13

The process of claim 11 wherein said hydrogen produced in said reformer zone is passed to said liquefaction zone.

Claim 14

The process of claim 1 wherein said liquefaction zone effluent stream is cooled before being separated into an effluent vapor stream and an effluent liquid slurry stream.

Claim 15

The process of claim 1 wherein said effluent vapor stream is passed through said catalytic hydrotreater without essentially any addition or removal of material therefrom.

Claim 16

The process of claim 1 including the additional step of recovering a heavy distillate stream from said hydrotreated product oil stream, and recycling said heavy distillate stream to said liquefaction zone.

Claim 17

The process of claim 1 wherein said hydrotreated product oil stream comprises substantially entirely white oil.

Claim 18

The process of claim 1 wherein said hydrotreated product oil stream boils substantially entirely below 700° F.

Claim 19

The process of claim 1 wherein said hydrotreated product oil stream boils substantially entirely below 600° F.

Claim 20

The process of claim 1 wherein said liquefaction pressure is 1,000 to 4,000 psi.

Claim 21

The process of claim 1 wherein said hydrotreated product oil stream comprises substantially entirely material in the naphtha, diesel oil and jet fuel boiling ranges.

Claim 22

The process of claim 1 wherein the yield of C 1 -C 4 gases is less than 9 weight percent, based on moisture-free feed coal.

Claim 23

The process of claim 1 wherein the yield of C 1 -C 4 gases is less than 8 weight percent, based on moisture-free feed coal.

Claim 24

The process of claim 1 wherein the oxygen content in the 193° C.+ distillate oil product is below 600 parts per million.

Claim 25

The process of claim 1 wherein the oxygen content in the 193° C.+ distillate oil product is below 500 parts per million.

Claim 26

The process of claim 1 wherein the oxygen content in the entire distillate oil product is less than 600 parts per million.

Claim 27

The process of claim 1 wherein the oxygen content in the entire distillate oil product is less than 500 parts per million.

Claim 28

The process of claim 1 wherein the oxygen content in the entire distillate oil product is less than 400 parts per million.

Claim 29

The process of claim 1 wherein the nitrogen content in the entire distillate oil product is less than 10 parts per million.

Claim 30

The process of claim 1 wherein the nitrogen content in the entire distillate oil product is less than 4 parts per million.

Claim 31

The process of claim 1 wherein the sulfur content in the entire distillate oil product is less than 600 parts per million.

Claim 32

The process of claim 1 wherein the sulfur content in the entire distillate oil product is less than 400 parts per million.

Claim 33

The process of claim 1 including the additional step of recovering a purified water phase from said hydrotreater effluent stream.

Claim 34

The process of claim 1 including the addition of an alkaline material to neutralize chlorine that tends to form ammonium chloride in said hydrotreater.

Claim 35

The process of claim 1 wherein said step of removing a liquefaction zone effluent stream occurs at essentially said liquefaction pressure.

Claim 36

The process of claim 1 wherein said step of passing said entire effluent vapor stream through said catalytic hydrotreater occurs at essentially said liquefaction pressure.

Claim 37

A process comprising liquefaction of feed coal in a liquefaction zone at liquefaction temperature, pressure and residence time in the presence of hydrogen with recycle solvent and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream comprising the hydrocarbons boiling above 550° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia, CO x and water vapor, passing said effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said effluent vapor stream, passing said effluent liquid slurry stream to an atmospheric distillation zone to recover an atmospheric distillate and an atmospheric residue slurry, recycling substantially said entire atmospheric distillate and a portion of said atmospheric residue slurry to said liquefaction zone, passing the remaining portion of said atmospheric residue slurry to a vacuum distillation zone to recover a vacuum distillate and a vacuum residue slurry, recycling substantially said entire vacuum distillate to said liquefaction zone, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.

Claim 38

A process comprising liquefaction of feed coal in a liquefaction zone at liquefaction temperature, pressure and residence time in the presence of hydrogen with recycle solvent and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream comprising the hydrocarbons boiling above 550° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia, CO x and water vapor, passing said effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said effluent vapor stream, passing said effluent liquid slurry stream to an atmospheric distillation zone to recover an atmospheric distillate and an atmospheric residue slurry, recycling substantially said entire atmospheric distillate and a portion of said atmospheric residue slurry to said liquefaction zone, passing the remaining portion of said atmospheric residue slurry to a vacuum distillation zone to recover a vacuum distillate and a vacuum residue slurry, recycling substantially said entire vacuum distillate to said liquefaction zone, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.

Claim 39

The process of claim 36 including the additional step of passing said vacuum residue slurry to a gasifier zone for the production of hydrogen.

Claim 40

The process of claim 36 wherein said step of removing a liquefaction zone effluent stream occurs at essentially said liquefaction pressure.

Claim 41

The process of claim 36 wherein said step of passing said effluent vapor stream through said catalytic hydrotreater occurs at essentially said liquefaction pressure.

Claim 42

The process of claim 36 wherein said effluent liquid slurry stream comprises the hydrocarbons boiling above 570° F.

Claim 43

The process of claim 36 wherein said effluent liquid slurry stream comprises the hydrocarbons boiling above 600° F.

Claim 44

The process of claim 36 wherein said effluent liquid slurry stream comprises the hydrocarbons boiling above 700° F.

Claim 45

A process comprising liquefying feed coal in a liquefaction zone at liquefaction conditions of temperature, pressure and residence time in the presence of hydrogen with recycle solvent including distillable and non-distillable coal liquids and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream comprising the hydrocarbons boiling above 600° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia, CO x and water vapor, passing said entire effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said vapor stream, removing distillate liquid from said effluent liquid slurry stream to obtain non-distillable coal liquids and recycling to said liquefaction zone to extinction the 600° F.+ fraction of said distillate liquid, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.

Claim 46

A process comprising liquefying feed coal in a liquefaction zone at liquefaction conditions of temperature, pressure and residence time in the presence of hydrogen with recycle solvent including distillable and non-distillable coal liquids and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream comprising the hydrocarbons boiling above 600° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia, CO x and water vapor, passing said entire effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said vapor stream, removing distillate liquid from said effluent liquid slurry stream to obtain non-distillable coal liquids and recycling to said liquefaction zone to extinction the 600° F.+ fraction of said distillate liquid, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.

Claim 47

A process comprising liquefying feed coal in a liquefaction zone at liquefaction conditions of temperature, pressure and residence time in the presence of hydrogen with recycle solvent including distillable and non-distillable coal liquids and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream comprising the hydrocarbons boiling above 590° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia, CO x and water vapor, passing said entire effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said vapor stream, removing distillate liquid from said effluent liquid slurry stream to obtain non-distillable coal liquids and recycling to said liquefaction zone to extinction the 590° F.+ fraction of said distillate liquid, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.

Claim 48

A process comprising liquefying feed coal in a liquefaction zone at liquefaction conditions of temperature, pressure and residence time in the presence of hydrogen with recycle solvent including distillable and non-distillable coal liquids and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream comprising the hydrocarbons boiling above 590° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia, CO x and water vapor, passing said entire effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said vapor stream, removing distillate liquid from said effluent liquid slurry stream to obtain non-distillable coal liquids and recycling to said liquefaction zone to extinction the 590° F.+ fraction of said distillate liquid, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.

Claim 49

A process comprising liquefying feed coal in a liquefaction zone at liquefaction conditions of temperature, pressure and residence time in the presence of hydrogen and recycle solvent including distillable and non-distillable coal liquids and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream comprising the hydrocarbons boiling above 570° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia and CO x and water vapor, passing said entire effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said vapor stream, removing distillate liquid from said effluent liquid slurry stream to obtain non-distillable coal liquids and recycling to said liquefaction zone to extinction the 570° F.+ fraction of said distillate liquid, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.

Claim 50

A process comprising liquefying feed coal in a liquefaction zone at liquefaction conditions of temperature, pressure and residence time in the presence of hydrogen and recycle solvent including distillable and non-distillable coal liquids and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream comprising the hydrocarbons boiling above 570° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia and CO x and water vapor, passing said entire effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said vapor stream, removing distillate liquid from said effluent liquid slurry stream to obtain non-distillable coal liquids and recycling to said liquefaction zone to extinction the 570° F.+ fraction of said distillate liquid, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.

Claim 51

A process comprising liquefying feed coal in a liquefaction zone at liquefaction conditions of temperature pressure and residence time in the presence of hydrogen with recycle solvent including distillable and non-distillable coal liquids and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream comprising the hydrocarbons boiling above 550° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia, CO x and water vapor, passing said entire effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said vapor stream, removing distillate liquid from said effluent liquid slurry stream to obtain non-distillable coal liquids and recycling to said liquefaction zone to extinction the 550° F.+ fraction of said distillate liquid, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.

Claim 52

A process comprising liquefying feed coal in a liquefaction zone at liquefaction conditions of temperature pressure and residence time in the presence of hydrogen with recycle solvent including distillable and non-distillable coal liquids and recycle coal minerals to produce coal liquids, removing a liquefaction zone effluent stream, separating said liquefaction zone effluent stream into an effluent vapor stream and an effluent liquid slurry stream comprising the hydrocarbons boiling above 550° F., said effluent vapor stream containing naphtha and higher and lower boiling hydrocarbons together with hydrogen, hydrogen sulfide, ammonia, CO x and water vapor, passing said entire effluent vapor stream through a vapor phase catalytic hydrotreater to hydrotreat said vapor stream, removing distillate liquid from said effluent liquid slurry stream to obtain non-distillable coal liquids and recycling to said liquefaction zone to extinction the 550° F.+ fraction of said distillate liquid, recovering a hydrotreater effluent stream, separating a hydrotreated product oil stream from said hydrotreater effluent stream, said hydrotreated product oil stream comprising substantially the entire distillate oil product of said process.